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6 Clamps, 1/8" drill, 18-gauge nail gun with 1" nails, drill block, 2.5" screws, 1.5" screws
Wipe off backers and shelves with a rag
Clamp the jig to the backer. Make sure the correct side is up.
Clamp the bracket to the jig.
Clamp shelf to the jig. Make sure it is centered in the backer. Clamp both sides together.
Drill through the top 4 holes of backer into shelf using the guide block. Keep drill vertical!
Use 1.5" screws on the two middle holes, and 2.5" screws on the outside holes.
Flip shelf over and adjust bracket so that both sides are flush on the shelf and backer. Shoot one 1" nail into the bracket and shelf.
Drill through the backer into the bracket. Don't go very far! Just start the hole so it won't split.
Attach the bracket with 1.5" screws through the holes you pre-drilled.
Shoot another nail right next to the first nail on BOTH brackets.
Unclamp all jigs. The shelf is finished.
Trophy Shelf Assembly FAQs
Why do we use a drill block?
It helps keep the bit straight as you drill. We have experimented with other methods that don't use the block, but that led to a lot of tear-out in the shelf.
There is a gap between the bracket and the shelf. How do I fix?
First try shooting another nail in, this time squeezing the bracket tight when firing. If that doesn't work, take the bracket off, pull the nails out, apply a small bead of wood glue to the bracket, and reattach.
Do I need to use 2 long screws and 2 short screws?
Yes and no. If you have to replace one of the long screws with a shorter one, it will work. I wouldn't risk replacing both though, people could be putting a lot of weight on these.
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